Medtech
Orthotics and Prosthetics
Every patient is unique. Your products should be, too.
Orthotics and prosthetics are ideal applications for 3D printing, bringing many advantages to both patients and professionals. Discover how you can take advantage of them all, from improving treatment plans through personalized devices to the added efficiency of design automation and simplified workflows.
Why choose 3D printing?
Simplified design-to-order workflow
Whether it’s moving from design to (re)order at the click of a button in footscan or taking advantage of in-house post-processing services, creating a finished part is faster and more efficient with AM.
No minimum order quantities
With no minimum order quantities, manufacturing with 3D printing can start at a series of one. Produce unique components on demand and eliminate the need for tooling or build high-quality masters for vacuum casting.
Why choose Materialise?
Materialise Motion
Our dedicated department — incorporating the former RSscan — specializes in dedicating end-to-end digital workflows based on dynamic gait analysis for foot and ankle specialists, including our footscan software and phits 3D-printed orthotics.
Dedicated quality management
The stringent requirements of the medical technology industry make quality control and traceability crucial in your production process. Our standardized NPI process for serial production guarantees repeatability, traceability, and high-quality products — all backed by quality management principles in accordance with ISO 9001 and a team experienced in bringing medical devices safely to the market.
Flexible production methods
Whether you’re producing a prototype or moving into serial production, our range of in-house production methods provides access to whichever technology best fits your purpose. Find everything from vacuum casting to 3D printing in polymers and metals, all in one place.
Industry-leading software for your AM production
Control and manage your entire production process with our industry-leading CO-AM Software Package. With CO-AM, you’ll have all the tools for a fully streamlined and scalable workflow, perfect for both qualified suppliers and internal 3D printing departments.
Expert advice on hand
When you need guidance in harnessing the potential of AM for your business, nothing beats first-hand experience. Our Mindware team works hand-in-hand with you to tackle your most pressing challenges, wherever you are on your AM journey. From strategic roadmaps and identifying key applications for AM to deploying full-scale production lines, you can count on us to get you there.
Dedicated to wearables
Whether it’s our history with custom-fit hearing aids or our dedicated production line for eyewear, our facilities, materials, and finishes are a perfect fit for products such as prosthetics. Our services are ideal for mass customization and bringing an individual personality to your products in line with your patient’s needs.
Ideal materials
PA 12 Medical-Grade (PA 2201)
Technology
Selective laser sintering
Description
PA 12 Medical-Grade offers high strength, chemical resistance, and detail resolution, making it ideal for high-quality and fully-functional biocompatible plastic parts for settings such as operating rooms. This material is subjected to testing for cytotoxicity, sensitization, irritation, acute systemic toxicity, and material-mediated pyrogenicity.
Key characteristics
- Biocompatible material
- High strength and stiffness
- Good chemical resistance
- High selectivity and detail resolution
- Max part dimensions: 170 x 215 x 320 mm
PA 11
Technology
Multi Jet Fusion
Description
Combining excellent mechanical properties with impressive surface quality and detail, this material is ideal for both series production and functional prototypes, especially in industries like medtech (O&P), aerospace, and automotive.
Key characteristics
- Flexible and stress-resistant
- Excellent surface detail and dimensional accuracy
- High density and isotropy
- Smooth surface quality with minimal post-processing
- Max part dimensions: 370 x 274 x 375 mm
PA 2210 FR
Technology
Selective laser sintering
Description
PA 2210 FR is a high-performance, UL Blue Card-certified polyamide containing a halogen-free flame retardant. Excellent long-term stability and good chemical resistance make it ideal for functional prototypes or end-use parts.
Key characteristics
- Strong material printed without a support structure
- Flame retardant — UL Blue Card-certified (UL 94 rating of V-0 at 3 mm wall thickness), CS/FAR 25.853 compliant
- High chemical, mechanical, and thermal resistance
- Max part dimensions: 280 x 280 x 550 mm
ABS-like Polyurethanes
Technology
Vacuum casting
Description
Offering a range of different material properties, our ABS-like polyurethanes can be used with silicone molds to produce high-quality prototypes or small series of end-use parts.
Key characteristics
- Excellent surface and detail, with injection-molded look and feel
- Flame-retardant, food-safe, and UV-stable materials available
- Cost-effective way to produce prototypes or small series of end-use parts
- Max part dimensions: 1,900 x 900 x 750 mm (maximum part volume: 10 liters)
Stainless Steel (SS316L)
Technology
Metal 3D printing
Description
Stainless Steel (SS316L) is a low-carbon stainless steel alloy that offers excellent strength, high corrosion resistance and ductility, and good thermal properties, making it suitable for general prototyping.
Key characteristics
- Excellent strength
- High corrosion, temperature, and chemical resistance
- High ductility
- Suitable for food-safe applications
- Max part dimensions: 250 x 250 x 305 mm
Titanium (Ti₆Al₄V)
Technology
Metal 3D printing
Description
Ti₆Al₄V is a lightweight titanium alloy with excellent mechanical strength and superior corrosion resistance, making it ideal for functional prototypes and high-performance end-use parts.
Key characteristics
- Excellent mechanical properties
- Lightweight, with a high strength-to-weight ratio
- High corrosion and temperature resistance
- Suitable for post-machining
- Max part dimensions: 250 x 250 x 305 mm
Ultrasint TPU 90A-01
Technology
Multi Jet Fusion
Description
Ultrasint TPU 90A-01 combines durable elasticity with good wear and abrasion resistance, making it ideal for prototypes and end-use applications that require good shock absorption.
Key characteristics
- Rubber-like material printed without a support structure
- Durable elasticity with high elongation at break
- Good wear and abrasion resistance, and good shock absorption
- Max part dimensions: 370 x 274 x 375 mm
Polypropylene (PP)
Technology
Selective laser sintering
Description
A tough, fatigue-resistant, and lightweight material, polypropylene (PP) is ideal for functional prototypes of snap-fit assemblies or living hinges in automotive components, packaging, and consumer goods.
Key characteristics
- Tough yet flexible material printed without a support structure
- Very high elongation at break (> 500%)
- Lightweight and fatigue resistant
- Max part dimensions: 480 x 480 x 430 mm
Typical applications
Prosthetic limbs and liners
Whether turning to 3D printing for its speed and freedom of design or relying on software to automate the design process and reduce the risk of errors, like in the case of Heygears, the technology is a proven game-changer for prosthetic limbs.
Rehabilitation aids
Mobility aids outside of prosthetics and orthotics, such as wheelchairs and exoskeletons, also benefit from 3D printing. Whether through lightweighting, personalization, or enabling scalability, it helps improve results for patients and manufacturers alike.
Our products and services
Ready to start your project with us? Discover our solutions, ideal for medtech.
Innovate and speed up your manufacturing in collaboration with our experts. Rely on our full range of in-house technologies suitable for all industries and applications.
Transform your product development cycle and get the best possible products to market faster. Get unbiased advice and dedicated support from teams committed to your success.
Get direct 24/7 access to the technologies and materials you need to bring your designs to life. Instant quotes, short lead-times, and easy checkout.
Build your success on a platform of software tools that efficiently manage and control the 3D printing process, allowing you to meet the highest standards of the most demanding industries.
Work with our experts to translate your business challenges into 3D printing opportunities and identify the applications that can help you meet your needs.
From bespoke surgical knee guides to true-to-life 3D-printed models of the human heart, our medical software and printing facilities are helping to bring personalized healthcare to everyone.
Discover the precise and seamless digital workflow designed by foot and ankle experts for foot and ankle experts based on scientific research
Connect and streamline your AM workflows to the production floor with business systems, machine connectivity, and solutions that improve quality output and ROI.
Inspiration
Get inspired for your next project with a look at how others have used 3D printing for medtech.
